Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)

21. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the No. 1 chain tensioner assembly with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.

(e) Check the camshaft timing marks.

NOTICE:
* Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
* If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
(f) Check that each camshaft timing mark is positioned as shown in the illustration.

HINT
For the intake camshaft:

Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(g) If the valve timing is misaligned, reinstall the timing chain.

(h) Remove the pulley set bolt.

23. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.

SST : 09223-22010

SST : 09506-35010

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.
24. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 8 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

NOTICE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 mm (0.118 in.)

NOTICE:
* Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
* If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes.
* Do not start the engine for at least 2 hours after installing.
(b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTICE:
* If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

Apply seal packing as follows:

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

(e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt length:

NOTICE:
Make sure that there is no oil on the bolt and nut threads.

(f) Fully tighten the bolts in this order: Area 1 and Area 2.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(g) Fully tighten the bolts in Area 3.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT
First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration.

(h) Fully tighten the bolts in Area 4.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf for bolt A)

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolts except bolt A)

HINT
Tighten the bolts in the order of lower to upper as shown in the illustration.

(i) Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf)

26. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to O-ring (A) in the illustration before installation.

(b) Install the 2 stud bolts.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(c) Install the water inlet housing with the 2 bolts and nut.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Be careful that the O-ring does not get caught between the parts.

(d) Connect the No. 1 water by-pass hose.

(e) Apply adhesive around the drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the drain cock assembly to the water inlet housing.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(g) Install the drain cock plug to the drain cock assembly.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT
The jiggle valve may be set within 10° of either side of the prescribed position.

(j) Install the water inlet with the 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

27. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Install the No. 1 front engine mounting bracket LH with the 6 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTICE:
* Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
* Do not start the engine for at least 2 hours after installation.
(b) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

28. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 7 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) as shown in the illustration before tightening the other bolts.

29. INSTALL OIL PAN SUB-ASSEMBLY

(a) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolt A)

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf for bolt B)

(b) Install 2 new O-rings.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(d) Install the oil pan with the 16 bolts and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolt A)

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for except bolt A)

30. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

31. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(c) Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

32. INSTALL OIL PAN DRAIN PLUG

(a) Install a new oil pan drain plug gasket and the oil pan drain plug.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surface.
* Install the head cover within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Install 3 new gaskets as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolt A)

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for except bolt A)

HINT
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Install 3 new gaskets as shown in the illustration.

(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

(d) Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolt A)

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for except bolt A)

HINT
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

35. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring.

HINT
Apply soapy water to the O-ring.

(b) Install the water outlet with the 2 bolts and 4 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolts)

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for nuts)

NOTICE:
Be careful that the O-ring does not get caught between the parts.

36. INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring and install it to the No. 1 engine oil level dipstick guide.

(b) Install the bolt and No. 2 dipstick guide.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

37. INSTALL NO. 1 OIL COOLER BRACKET (w/ OIL COOLER)

(a) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Install a new gasket to the No. 1 oil cooler bracket.

(c) Install the oil cooler pipe with the bolt and 2 nuts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

(d) Install a new gasket to the No. 1 oil pan.

(e) Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

38. INSTALL OIL COOLER ASSEMBLY (w/ OIL COOLER)

(a) Install a new O-ring.

(b) Install the oil cooler assembly with the union bolt.

Torque : 68 Nm (693 kgf-cm, 50 ft-lbf)

(c) Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

39. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

SST : 09213-70011

09213-70020

SST : 09330-00021

Torque : 250 Nm (2550 kgf-cm, 184 ft-lbf)

40. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove.

(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.

(c) Set a new oil filter element to the oil filter cap sub-assembly.

(d) Remove dirt and foreign matter from the installation surface of the engine.

(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.

NOTICE:
* Be careful that the O-ring does not get caught between any parts.
* The O-ring must not be twisted on the groove.
(f) Using SST, tighten the oil filter cap sub-assembly.

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Make sure that the oil filter is installed securely as shown in the illustration.

(g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

NOTICE:
Remove all dirt and foreign matter from the installation surfaces.

(h) Install the oil filter drain plug to the oil filter cap sub-assembly.

Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)

NOTICE:
Make sure that the O-ring does not get caught between the parts.

41. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

42. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.

(c) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

(d) Tighten the oil pipe union (on the cylinder head side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

(e) Tighten the oil pipe union (on the head cover side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

43. INSTALL OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.

(c) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

(d) Tighten the oil pipe union (on the cylinder head side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

(e) Tighten the oil pipe union (on the head cover side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

(f) Install the bolt (A) to the cylinder head.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

44. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

45. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 camshaft timing oil control valves with the 4 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

46. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the 4 camshaft position sensors with the 4 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

47. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve sub-assembly.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

48. INSTALL SPARK PLUG

(a) Install the 6 spark plugs.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

49. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler gasket.

(b) Install the oil filler cap sub-assembly.